The
Reactor is the most commonly used physical mixing or chemical reactor, through the structural design and parameter configuration of the vessel, to achieve the process requirements on heating, evaporation, cooling and low-speed mixing functions. It is widely used in medicine, food, chemical industry, rubber, pesticides, dyestuffs, and is a pressure vessel used to complete the process of synthesis, oxidation, sulphidation, nitration, hydrogenation, hydrocarbonisation, polymerisation, condensation, etc.
For the application of the reactor, we often encounter such and such abnormal phenomena, the following combined with the actual process of chemical production summed up the reactor common 8 kinds of failure and elimination methods.
one. Failure phenomenon: shell damage (corrosion, cracks, perforation)
Failure causes.
1. by the medium radiation (pitting, intergranular corrosion).
2. The impact of thermal stress to produce cracks or alkali brittle.
3. Wear thinning or uniform corrosion.
Treatment methods.
1. the use of corrosion-resistant materials lining the shell need to be relined or local patch welding.
2. After welding, stress should be removed and cracks should be repaired.
3. More than the minimum allowable thickness of the design, the body needs to be replaced.
Second, the phenomenon of failure: over temperature and over pressure
Cause of failure.
1. Instrument failure, control is not strict.
2. Misoperation; improper proportioning of raw materials; violent reaction
3. Poor heat transfer or stirring performance, resulting in side reactions.
4. Inlet valve failure resulting in excessive pressure and high pressure
Treatment method.
1. Check and repair the automatic control system, and strictly implement the operation procedures.
2. According to the operation method, take emergency pressure release, feed according to the specified quantity and time, and strictly prevent misoperation.
3. Increase the heat transfer area or remove the scale to improve the heat transfer effect and repair the stirrer to improve the stirring efficiency.
4. Close the main steam valve and repair the valve by cutting off the steam.
Three, the failure phenomenon: seal leakage
Fault phenomenon: (1) Packing seal
(1) Packing seal:
1. stirring shaft at the packing wear or corrosion, resulting in excessive clearance;
2. Improperly positioned oil ring or blocked oil circuit cannot form an oil seal;
3. The gland is not pressed tightly, the packing quality is poor, or it has been used for too long;
4. Corrosion of the stuffing box.
(2) Mechanical seal:
1. deformation of the static and dynamic ring end face, bruising;
2. End surface pressure is too large, the friction side of the thermal deformation;
3. Incorrect material selection of sealing ring, insufficient compression force, or V-shaped sealing ring installed in reverse, loss of sealing;
4. The vertical error between the axis and the end face of the static ring is too large;
5. operating pressure, temperature instability, hard particles into the friction side;
6. The amount of shaft string exceeds the target;
7. The inlay or glued dynamic and static ring inlay leakage.
Treatment methods:
(1) Packing seal
1. Replace or repair the mixing shaft and process it on the machine tool to ensure roughness;
2. adjust the position of the oil ring and clean the oil circuit;
3. pressing the packing, or replacing the packing;
4. repairing or replacing;
(2) Mechanical seal
1. replace the friction pair or regrind;
2. adjust the ratio pressure to be appropriate, strengthen the cooling system, and take away the heat in time;
3. seal selection, installation to be reasonable, to have sufficient compression force;
4. stop the machine, re-righting, to ensure that the non-vertical degree is less than 0.5 mm;
5. Strict control of process indicators, particles and crystalline matter can not enter the friction sub;
6. Adjustment and overhaul to make the shaft tampering amount reach the standard;
7. Improve the installation process, or the amount of interference should be appropriate, or the adhesive should be good and firm.
four. Failure phenomenon: abnormal noise in the kettle
Cause of failure.
1. The stirrer rubs against the kettle accessories (snake tube, thermometer tube, etc.) or scrapes the biscuit.
2. The stirrer is loose.
3. The lining is bulging and hitting the stirrer.
4. Stirrer bent or bearing damaged.
Treatment.
1. Stop the machine for maintenance and correct it, so that the agitator and the accessories have a certain distance.
2. Stop the machine for inspection and tighten the bolts.
3. Repair the bulb, or replace the lining.
4. Repair or replace the shaft and bearings.
Five, the failure phenomenon: enamel stirrer off
Failure causes:
1. fracture by medium corrosion;
2. Motor rotation in the opposite direction.
Treatment methods:
1. Replace the enamel shaft or repair with glass steel.
2. Stop and change the direction of rotation.
Six, the failure phenomenon: porcelain-lined kettle flange air leakage
Failure causes:
1. damage to the porcelain surface of the flange;
2. unreasonable choice of gasket material, incorrect installation joint, empty position, misshift;
3. Loose clips or insufficient number of clips.
Treatment methods:
1. repair, coating anti-corrosion paint or resin;
2. according to the process requirements, the choice of gasket material, gasket interface to lap together, the position should be uniform;
3. According to the design requirements, there is a sufficient number of snaps, and to fasten.
Seven, the failure phenomenon: porcelain surface to produce scale explosion and microporous
Failure causes:
1. jacket or stirring shaft tube into the acidic impurities, resulting in hydrogen embrittlement phenomenon;
2. The porcelain layer is not dense and has microporous potential.
Treatment methods:
1. use sodium carbonate to neutralize, flush with water or repair, serious corrosion needs to be replaced;
2. The number of microporous can be repaired, serious update.
Eight, fault phenomenon: motor current exceeds the rated value
Failure causes:
1. Bearing damage;
2. Low temperature in the kettle and sticky material;
3. Faster spindle speed;
4. The diameter of the stirrer is too large.
Handling methods:
1. Replace the bearing;
2. Adjust the temperature according to the operating procedures, the viscosity of the material should not be too large;
3. control the spindle speed within a certain range;
4. Adjust appropriately.
Source: Reprint
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